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Image
Valve-spring failure due to residual shrinkage pipe. (a) Macrograph showing...
Available to PurchasePublished: 01 January 2002
Fig. 13 Valve-spring failure due to residual shrinkage pipe. (a) Macrograph showing fracture, as indicated by arrow. (b) Fracture surface; pipe is indicated by arrow.
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Image
Valve-spring failure due to residual shrinkage pipe. (a) Macrograph showing...
Available to PurchasePublished: 01 January 2002
Fig. 3 Valve-spring failure due to residual shrinkage pipe. (a) Macrograph showing fracture as indicated by arrow. (b) Fracture surface; pipe is indicated by arrow.
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Book Chapter
Failures Related to Metalworking
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003507
EISBN: 978-1-62708-180-1
... discusses the types of imperfections that can be traced to the original ingot product. These include chemical segregation; ingot pipe, porosity, and centerline shrinkage; high hydrogen content; nonmetallic inclusions; unmelted electrodes and shelf; and cracks, laminations, seams, pits, blisters, and scabs...
Abstract
This article describes the general root causes of failure associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be the common sources of failure-inducing defects in bulk working of wrought products. The article discusses the types of imperfections that can be traced to the original ingot product. These include chemical segregation; ingot pipe, porosity, and centerline shrinkage; high hydrogen content; nonmetallic inclusions; unmelted electrodes and shelf; and cracks, laminations, seams, pits, blisters, and scabs. The article provides a discussion on the imperfections found in steel forgings. The problems encountered in sheet metal forming are also discussed. The article concludes with information on the causes of failure in cold formed parts.
Book Chapter
Riser Design
Available to PurchaseBook: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0009016
EISBN: 978-1-62708-187-0
... method takes the typical conical shape of the shrinkage cavity formed in a riser as it simultaneously feeds metal into the casting and solidifies inward from its walls ( Fig. 18 ) and simplifies it to the configuration of a cylindrical pipe ( Ref 23 ). The size of this pipe depends on the weight...
Abstract
The role of an engineer in designing risers is to make sure that risers provide the feed metal in the right amount, at the right place, and at the right time. This article addresses feed metal volume, riser location, and duration of liquid feed metal. It discusses the three types of feeding systems used in riser design: riser sleeves, topping compounds, and breaker cores.
Image
Valve-spring failure due to residual shrinkage during solidification. (a) M...
Available to PurchasePublished: 30 August 2021
Fig. 1 Valve-spring failure due to residual shrinkage during solidification. (a) Macrograph showing fracture, as indicated by arrow. (b) Fracture surface; pipe is indicated by arrow. Source: Ref 4
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Book Chapter
Failures Related to Hot Forming Processes
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006835
EISBN: 978-1-62708-329-4
... also occur. Subsurface flaws often (but not always) originate from the as-cast ingot due to shrinkage, voids, and porosity that form during solidification. Figure 1 illustrates how rolled bar may contain porosity and pipe imperfections carried over from the cast ingot. These imperfections can serve...
Abstract
The primary purpose of this article is to describe general root causes of failure that are associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be common sources of failure-inducing defects in the bulk working of wrought products. The article addresses the types of flaws or defects that can be introduced during the steel forging process itself, including defects originating in the ingot-casting process. Defects found in nonferrous forgings—titanium, aluminum, and copper and copper alloys—also are covered.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003170
EISBN: 978-1-62708-199-3
... Abstract Metal casting is the manufacturing method in which a metal or an alloy is melted, poured into a mold, and allowed to solidify. Typical uses of castings include municipal hardware, water distribution systems (pipes, pumps, and valves), automotive components (engine blocks, brakes...
Abstract
Metal casting is the manufacturing method in which a metal or an alloy is melted, poured into a mold, and allowed to solidify. Typical uses of castings include municipal hardware, water distribution systems (pipes, pumps, and valves), automotive components (engine blocks, brakes, steering and suspension components, etc.), prosthetics, and gas turbine engine hardware. This introduction explains the steps involved in making a casting using a simplified flow diagram, and discusses the ferrous and nonferrous alloys used for metal casting.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005257
EISBN: 978-1-62708-187-0
... the need for a central core in the pipe mold, and the mold was water cooled, allowing for a high rate of repeated use. The technique uses the centrifugal force generated by a rotating cylindrical mold to throw molten metal against a mold wall to form the desired shape. Therefore, a centrifugal casting...
Abstract
This article describes the applications, advantages, and disadvantages of three centrifugal casting processes as well as the equipment used. These processes are true centrifugal casting, semicentrifugal casting, and centrifuge mold casting. The article discusses the cooling, inoculation, fluxing, and extraction of castings. It reviews mold heating and coating techniques as well as the various molds used. The three most common defects observed in centrifugal castings are also discussed. The article concludes with information on the applications of centrifugal casting in investment casting and combustion synthesis as well as spin casting.
Book Chapter
Fusible Alloys
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003161
EISBN: 978-1-62708-199-3
... elevated temperature, however, the fusible alloy link will melt, thus disconnecting the parts. In fire sprinklers, the links melt when dangerous temperatures are reached, releasing water from piping systems and extinguishing the fire. Boiler plugs and furnace controls react similarly because an increase...
Abstract
Fusible alloys, eutectic and noneutectic, include a group of binary, ternary, quaternary, and quinary alloys containing bismuth, lead, tin, cadmium, and indium that melt at relatively low temperatures. This article describes the composition and mechanical properties of these alloys and lists the values of their composition and melting temperatures.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003621
EISBN: 978-1-62708-182-5
... close to the material yield stress, remain as a result of weld shrinkage. Stress-concentration effects as a result of geometrical discontinuities, such as weld reinforcement (excess weld metal) and lack of full weld penetration (dangerous because of the likelihood of crevice corrosion...
Abstract
Corrosion of carbon steel weldments can be due to metallurgical effects, such as preferential corrosion of the heat-affected zone (HAZ) or weld metal, or it can be associated with geometrical aspects, such as stress concentration at the weld toe, or creation of crevices due to joint design. This article describes the issues related to corrosion of carbon steel weldments and the remedial measures that have proven to be successful in specific cases. It provides useful information on preferential HAZ corrosion, preferential weld metal corrosion, and galvanic corrosion.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003171
EISBN: 978-1-62708-199-3
... shrinkage. This article describes the imperfections in the solidification process including porosity, inclusions, oxide films, secondary phases, hot tears, and metal penetration. It talks about the purpose of the gating system and the risering system in the casting process. alloys casting gating...
Abstract
Solidification is a comprehensive process of transformation of the melt of metals and alloys into a solid piece, involving formation of dendrites, segregation which involves change in composition, zone formation in final structure of the casting, and microporosity formation during shrinkage. This article describes the imperfections in the solidification process including porosity, inclusions, oxide films, secondary phases, hot tears, and metal penetration. It talks about the purpose of the gating system and the risering system in the casting process.
Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002491
EISBN: 978-1-62708-194-8
... Details and design considerations for injection molding include shrinkage, postmold shrinkage, and size and location of holes and other features. Shrinkage Shrinkage occurs because the plastic melt volume is greater than the solid volume, and the plastic melt is packed into the mold under high...
Abstract
This article describes key processing methods and related design, manufacturing, and application considerations for plastic parts. The methods include injection molding, extrusion, thermoforming, blow molding, rotational molding, compression molding/transfer molding, composites processing, and casting. The article describes principal features incorporated into the design of plastic parts. It concludes with a discussion on the materials selection methodology for plastics.
Book Chapter
Microfractography and Metallography for Failure Analysis
Available to PurchaseSeries: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006760
EISBN: 978-1-62708-295-2
.... Nital etch. Transverse and (b) longitudinal sections. (c) Copper water pipe. Ferric chloride etch. Transverse and (d) longitudinal sections Cleaning Fracture Surfaces The practices that should be used when cleaning fracture surfaces are: Use the mildest agent possible and take care...
Abstract
Visual examination, using the unaided eye or a low-power optical magnifier, is typically one of the first steps in a failure investigation. This article presents the guidelines for selecting samples for scanning electron microscope examination and optical metallography and for cleaning fracture surfaces. It discusses damage characterization of metals, covering various factors that influence the damage, namely stress, aggressive environment, temperature, and discontinuities.
Series: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006038
EISBN: 978-1-62708-172-6
... into the types of polymer-based coatings that are both cost-effective and widely accepted in the pipeline industry. Why Do We Need Pipeline Coatings? Corrosion is the greatest danger to buried steel pipelines. Uncontrolled corrosion of the pipe wall leads to leaks, service interruptions, and even...
Abstract
This article describes the coating materials, surface-preparation requirements, and application techniques used to protect underground pipelines. It provides a valuable insight into the types of polymer-based coatings that are both cost-effective and widely accepted in the pipeline industry.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001475
EISBN: 978-1-62708-173-3
... Because a weldment is locally heated by the welding heat source, the temperature distribution is not uniform and changes as welding progresses. During the welding thermal cycle, complex transient thermal stresses are produced in the weldment and the surrounding joint. The weldment also undergoes shrinkage...
Abstract
This article describes the formation of residual stresses and distortion, providing information on the techniques for measuring residual stresses. It presents a detailed discussion on the magnitude and distribution analysis of the residual stresses and distortion in weldments. The article briefly explains the effects of residual stresses and distortion on the brittle fracture and fatigue fracture of welded structures. It also provides information on the thermal treatments of weldments.
Book Chapter
Service Lifetime Assessment of Polymeric Products
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006921
EISBN: 978-1-62708-395-9
... functions in the manner that was intended, then the product has failed. Typically, failure of a product is associated with cracking or fracture; however, excessive plastic deformation, shrinkage, wear, or worsened appearance may also constitute a failure just as much as a fracture does. Failures associated...
Abstract
The lifetime assessment of polymeric products is complicated, and if the methodology utilized leads to inaccurate predictions, the mistakes could lead to financial loss as well as potential loss of life, depending on the service application of the product. This article provides information on the common aging mechanisms of polymeric materials and the common accelerated testing methods used to obtain relevant data that are used with the prediction models that enable service life assessment. Beginning with a discussion of what constitutes a product failure, this article then reviews four of the eight major aging mechanisms, namely environmental stress cracking, chemical degradation, creep, and fatigue, as well as the methods used in product service lifetime assessment for them. Later, several methods of service lifetime prediction that have gained industry-wide acceptance, namely the hydrostatic design basis approach, Miner's rule, the Arrhenius model, and the Paris Law for fatigue crack propagation, are discussed.
Book Chapter
Failures Related to Welding
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003509
EISBN: 978-1-62708-180-1
... cracks are potential sources of failure because, although frequently small, they usually exist at the end of the weld where stress concentration is greatest. Their occurrence may be minimized by pausing before breaking the arc, by breaking and restarting the arc several times to feed the shrinkage pipe...
Abstract
This article briefly reviews the general causes of weldment failures, which may arise from rejection after inspection or failure to pass mechanical testing as well as loss of function in service. It focuses on the general discontinuities observed in welds, and shows how some imperfections may be tolerable and how the other may be root-cause defects in service failures. The article explains the effects of joint design on weldment integrity. It outlines the origins of failure associated with the inherent discontinuity of welds and the imperfections that might be introduced from arc welding processes. The article also describes failure origins in other welding processes, such as electroslag welds, electrogas welds, flash welds, upset butt welds, flash welds, electron and laser beam weld, and high-frequency induction welds.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005617
EISBN: 978-1-62708-174-0
... and the surrounding joint. The weldment also undergoes shrinkage and deformation during solidification and cooling. Thermal Stresses during Welding Figure 1 schematically shows changes in temperature and resulting stresses that occur during welding by examining a bead-on-plate weld of a thin plate made along...
Abstract
This article describes the formation of residual stresses and distortion and the techniques for measuring residual stresses. It provides a discussion on the magnitude and distribution analysis of residual stresses and distortion in weldments. The article considers the effects of residual stresses and distortion on the brittle fracture and fatigue fracture of welded structures. The thermal treatments of weldments are also discussed.
Series: ASM Handbook
Volume: 17
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.hb.v17.a0006455
EISBN: 978-1-62708-190-0
Abstract
Film radiography requires the development of the exposed film so that the latent image becomes visible for viewing. It describes the general characteristics of film, including speed, gradient, and graininess, and the factors affecting film selection and exposure time. The article discusses the three major inspection techniques for tubular sections, namely, the double-wall, double-image technique; the double-wall, single-image technique; and the single-wall, single-image technique. It illustrates the arrangements of penetrameters and identification markers for the radiography of plates, cylinders, and flanges. The article discusses various control methods, including the use of lead screens; protection against backscatter and scatter from external objects; and the use of masks, diaphragms, collimators, and filtration. The radiographic appearance of specific types of flaws is also discussed. The article concludes with a discussion on two methods of radiographic film processing: manual and automatic processing.
Book Chapter
Guidance for the Use of Protective Coatings in Municipal Potable Water Systems
Available to PurchaseSeries: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006040
EISBN: 978-1-62708-172-6
... coatings in these municipal water systems. The most commonplace corrosion-damage mechanisms are highlighted. The article describes the most common materials of construction found in municipal water systems, namely, cast iron, ductile iron, carbon steel, precast concrete cylinder pipe and reinforced...
Abstract
This article presents information regarding the use of protective coatings in municipal potable water systems, including raw water collection and transmission, water treatment plants, and treated water distribution. It provides useful guidance for the selection and use of protective coatings in these municipal water systems. The most commonplace corrosion-damage mechanisms are highlighted. The article describes the most common materials of construction found in municipal water systems, namely, cast iron, ductile iron, carbon steel, precast concrete cylinder pipe and reinforced concrete pipe, prestressed concrete tanks, and stainless steel. It provides information on the most common generic coating systems used for new steel tanks and water storage tanks. It concludes with a discussion of quality watch-outs when selecting or using protective coatings in municipal water systems.
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